Wall Panel

ABSTRACT

A wall panel includes a pair of plates and a plurality of vertical supports. The plates are spaced apart and parallel to one another. The vertical supports are affixed between the two plates. Each vertical support has a longitudinal axis parallel to the longitudinal axis of each other vertical support. Each vertical support has a width dimension parallel with the two plates and perpendicular to the longitudinal axis of the vertical support. At least one of the plates extends beyond at least one of the vertical supports a distance of a partial width of the vertical support.

BACKGROUND OF THE INVENTION

Wall panel systems include prefabricated wall panels and joints which are used to create a wall. These systems are suitable for many types of environments. In particular, wall panel systems may be useful when constructing secure holding facilities such as jails and prisons.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary floor plan of a room constructed using the present invention wall panel system.

FIG. 2 is a diagram showing a portion of the structure of one embodiment of a wall panel of the present invention.

FIGS. 3-9 are cross section diagrams showing the structure of different embodiments of wall panels of the present invention.

FIG. 10 is a cross section diagram showing the structure of one embodiment of a joint of the system of the present invention.

FIG. 11 is a diagram illustrating one embodiment for mounting the wall panels of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows one example of a wall panel system 2 of the present invention. Wall panel system 2 includes a plurality of wall panels 4. In one embodiment, system 2 further includes at least one corner joint 6.

FIG. 2 shows a portion of the structure of one embodiment of a wall panel 4 of the present invention. FIGS. 3-9 are cross sectional diagrams illustrating alternative embodiments of wall panels 4.

Each wall panel 4 includes plates 8, 10 and vertical supports 12. Plates 8, 10 are generally parallel to one another and spaced apart. Each plate 8, 10 may be constructed of any suitable plate material. For example, plates 8, 10 may be constructed of twelve gage steel. Each plate 8, 10 is sized as desired for the application.

Vertical supports 12 are affixed between the plates 8, 10. Supports 12 are affixed to plates 8, 10 by any suitable means. For example, supports 12 may be affixed to plates 8, 10 by welding, riveting, screwing, or nailing. Support 12 may be constructed of any suitably rigid material. For example, supports 12 may be constructed of 2″×2″×⅛″ steel tube material. While FIGS. 4-9 show only two vertical supports 12 for each wall panel 4, the present invention may be practiced with any plurality of supports 12 in each wall panel 4, similarly to FIG. 3.

Each vertical support 12 has a longitudinal axis 14 parallel to the longitudinal axis 14 of each other vertical support 12. Each vertical support 12 also has a width dimension 16 parallel with plates 8, 10 and perpendicular to longitudinal axis 14 of vertical support 12.

At least one of the plates 8, 10 extends beyond at least one of the vertical supports 12 a distance of a partial width 16 of the vertical support 12. In addition, at least one of the vertical supports 12 may extend beyond at least one of the plates 8, 10 a distance of a partial width 16 of the vertical support 12.

In one embodiment of wall panel 4, each vertical support 12 has a thickness dimension 18 perpendicular to plates 8, 10. Width 16 of vertical support 12 is equal to thickness 18 of vertical support 12. In one embodiment, vertical supports 12 are tubes. In one embodiment, vertical supports 12 have a rectangular cross section. In one embodiment, vertical supports 12 have a square cross section, such as a 2″×2″ square.

In one embodiment, wall panels 4 further includes horizontal support 20 affixed between plates 8, 10. Horizontal support 20 has a longitudinal axis 22 perpendicular to longitudinal axis 14 of each vertical support 12 of wall panel 4.

When assembled to form wall system 2, at least one plate 8, 10 of at least one of the wall panels 4 overlaps at least one of the vertical supports 12 of at least another one of the wall panels 4. This overlapping of plates 8,10 and supports enables wall system 2 to be easily assembled into a structurally cohesive integral unit. In one embodiment of wall system 2, at least one vertical support 12 of at least one of the wall panels 4 abuts at least one of the vertical supports 12 of at least another one of the wall panels 4.

FIG. 10 is a cross section diagram showing the structure of one embodiment of a corner joint 6. Each corner joint 6 includes plates 26-32 and vertical supports 12. Plates 26, 28 are generally parallel to one another and plates 30, 32 are generally parallel to one another. Plates 30, 32 are nonparallel to plates 26, 28 and affixed at one end to one end of plates 26, 28, respectively.

At least one vertical support 12 is affixed between plates 26, 28 and at least one vertical support 12 is affixed between plates 30, 32. Each vertical support 12 has a longitudinal axis 14 parallel to the longitudinal axis 14 of each other vertical support 12.

At least one of plates 26-32 of corner joint 6 extends beyond at least one of the vertical supports 12 a distance of a partial width 16 of the vertical support 12. When assembled with wall panels 4, at least one plate 26-32 of at least one of the wall panels 4 overlaps at least one of the vertical supports 12 of at least one of the corner joints 6.

Wall panel 4 may be mounted by any suitable means. FIG. 11 is a diagram illustrating one embodiment for mounting wall panels 4. A bent plate track 34 is installed onto the floor 36. Bent plate track 34 may be installed by any suitable means. For example, bent plate track 34 may be installed using an epoxy or anchors 36. Wall panel 4 is inserted into and attached to bent plate track 34. Wall panel 4 may then be filled with grout or insulation 38, or left unfilled.

The foregoing description is only illustrative of the invention. Various alternatives, modifications, and variances can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention embraces all such alternatives, modifications, and variances that fall within the scope of the described invention. 

1. A wall panel comprising: first and second spaced apart parallel plates; a plurality of vertical supports affixed between the first and second plates, each vertical support having a longitudinal axis parallel to the longitudinal axis of each other vertical support; wherein each vertical support has a width dimension parallel with the first and second plates and perpendicular to the longitudinal axis of the vertical support; and wherein at least one of the plates extends beyond at least one of the vertical supports a distance of a partial width of the vertical support.
 2. The wall panel of claim 1 wherein at least one of the vertical supports extends beyond at least one of the plates a distance of a partial width of the vertical support.
 3. The wall panel of claim 1 wherein each vertical support has a thickness dimension perpendicular to the first and second plates and the width of the vertical support is equal to the thickness of the vertical support.
 4. The wall panel of claim 1 wherein each vertical support is a tube.
 5. The wall panel of claim 4 wherein each vertical support has a rectangular cross section.
 6. The wall panel of claim 4 wherein each vertical support has a square cross section.
 7. The wall panel of claim 1 further including a horizontal support affixed between the first and second plates, the horizontal support having a longitudinal axis perpendicular to the longitudinal axis of each vertical support.
 8. A wall panel system comprising: a plurality of wall panels, each wall panel including: first and second spaced apart parallel plates; a plurality of vertical supports affixed between the first and second plates, each vertical support having a longitudinal axis parallel to the longitudinal axis of each other vertical support; wherein each vertical support has a width dimension parallel with the first and second plates and perpendicular to the longitudinal axis of the vertical support; and wherein at least one of the plates extends beyond at least one of the vertical supports a distance of a partial width of the vertical support; and wherein at least one plate of at least one of the wall panels overlaps at least one of the vertical supports of at least another one of the wall panels.
 9. The wall panel system of claim 8 wherein at least one vertical support of at least one of the wall panels abuts at least one of the vertical supports of at least another one of the wall panels.
 10. The wall panel system of claim 8 wherein at least one of the vertical supports extends beyond at least one of the plates a distance of a partial width of the vertical support.
 11. The wall panel system of claim 8 wherein each vertical support has a thickness dimension perpendicular to the first and second plates and the width of the vertical support is equal to the thickness of the vertical support.
 12. The wall panel system of claim 8 wherein each vertical support is a tube.
 13. The wall panel system of claim 12 wherein each vertical support has a rectangular cross section.
 14. The wall panel system of claim 12 wherein each vertical support has a square cross section.
 15. The wall panel of claim 8 wherein each wall panel further includes a horizontal support affixed between the first and second plates, the horizontal support having a longitudinal axis perpendicular to the longitudinal axis of each vertical support of the wall panel.
 16. The wall panel system of claim 8 further including at least one corner joint having: third and fourth spaced apart parallel plates; fifth and sixth spaced apart parallel plates, the fifth and sixth plates nonparallel to the third and fourth plates, the fifth plate affixed at one end to one end of the third plate and the sixth plate affixed at one end to one end of the fourth plate; at least one vertical support affixed between the third and fourth plates, each vertical support having a longitudinal axis parallel to the longitudinal axis of each other vertical support; at least one vertical support affixed between the fifth and sixth plates, each vertical support having a longitudinal axis parallel to the longitudinal axis of each other vertical support; wherein at least one of plates of the corner joint extends beyond at least one of the vertical supports a distance of a partial width of the vertical support; and wherein at least one plate of at least one of the wall panels overlaps at least one of the vertical supports of at least one of the corner joints. 